Method of delivering a discrete cord to a transfer member

ABSTRACT

A method of delivering a discrete cord to a transfer member, wherein the method includes providing a supply path fluidly connected to a metered cord supply. The supply path comprises a fluid flow, a transfer member, and a cutting apparatus. The transfer member comprises a first surface, a second surface, and a plurality of orifices on the first surface. The method also comprises moving a deployed cord supply towards the transfer member through the supply path by the fluid flow. The method further comprises moving a portion of the deployed cord supply into an orifice of the transfer member and cutting the deployed cord supply to create a discrete cord comprising a first end and a second end; wherein a portion of the discrete cord is in the orifice to the transfer member.

FIELD OF INVENTION

The present disclosure relates to a method for delivering a discretecord to a transfer member, and more particularly, to a method fordelivering a discrete cord to a transfer member utilizing fluid flow ina supply path.

BACKGROUND OF THE INVENTION

Withdrawal cords are commonly sewn onto tampons to help ease in theremoval of the tampon from the vaginal cavity. Typically, during themanufacturing process, a continuous cord is sewn onto multiple pledgetsthereby connecting the pledgets. The pledgets may be spaced on aconveyor connected by the continuous cord. The amount of cord betweentwo pledgets may comprise the amount of cord that is not sewn to thepledget, which represents the graspable portion of a withdrawal cord.The cord is then cut between pledgets in a separate process; leaving aportion of the cord attached to the pledget prior to the location of thecut and portion of the cord attached to a pledget after the location ofthe cut. The typical process also sews the cord onto the entirelongitudinal length of the pledget. This leads to unnecessary sewingthat utilizes excess sewing thread and cord. This process also createsinefficiency because the conveyor must space the pledgets to account forthe desired length of cord between pledgets.

The typical process ideally cuts the cord without cutting any of thepledgets. However, often, one or more pledgets are partially cut whencutting the cord. This leads to irregular pledgets that are discardedbecause they do not meet the product target.

Therefore, it would be desirable to provide a method and apparatus fordelivering a discrete cord to a transfer member through a supply path.The transfer member may move the discrete cord to an attachment systemcapable of attaching a single discrete cord to a pledget. This allowsfor a reduced sewing requirement per pledget while possibly increasingthe pledget production rate.

SUMMARY OF THE INVENTION

A method of delivering a discrete cord to a transfer member, wherein themethod includes providing a supply path fluidly connected to a meteredcord supply. The supply path comprises a fluid flow, a transfer member,and a cutting apparatus. The transfer member comprises a first surface,a second surface, and a plurality of orifices on the first surface. Themethod also comprises moving a deployed cord supply towards the transfermember through the supply path by the fluid flow. The method furthercomprises moving the deployed cord supply into an orifice of thetransfer member and cutting the deployed cord supply to create adiscrete cord comprising a first end and a second end; wherein a portionof the discrete cord is in the orifice to the transfer member.

A method of delivering a discrete cord to an attachment system, whereinthe method includes providing a supply path fluidly connected to ametered cord supply. The supply path comprises a receiving chamber, afluid flow, a cutting apparatus, and a transfer member comprising aplurality of apertures, a first surface in contact with the cuttingapparatus, and a second surface in contact with the receiving chamber.The method also includes moving a deployed cord supply towards thetransfer member through the supply path by the fluid flow. The methodfurther includes moving the deployed cord supply into an aperture of thetransfer member and cutting the deployed cord supply to create adiscrete cord comprising a first end and a second end; wherein a portionof the discrete cord is in the aperture of the transfer member. Themethod includes moving the aperture out of the fluid flow and contactingthe discrete cord with an attachment system.

A method of delivering a discrete cord to an attachment system, whereinthe method includes providing a supply path fluidly connected to ametered cord supply. The supply path comprises a receiving chamber, afluid flow, a cutting apparatus, and a transfer member comprising aplurality of apertures, a first surface in contact with the cuttingapparatus, and a second surface in contact with the receiving chamber.The method includes moving a deployed cord supply towards the transfermember through the supply path by the fluid flow. The method furtherincludes moving the deployed cord supply into an aperture of thetransfer member, contacting the deployed cord supply with a springloaded wheel, and cutting the deployed cord supply to create a discretecord comprising a first end and a second end with a knife connected to arotary axis; wherein a portion of the discrete cord is in the apertureof the transfer member. The method includes deflecting the discrete cordby an outlet in the receiving chamber, moving the transfer memberaperture out of the fluid flow, and contacting the discrete cord with anattachment system. The metered cord supply, the cutting apparatus, andthe transfer member work in unison providing one discrete cord to everyaperture of the transfer member that enters the fluid flow.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter of the present invention, itis believed that the invention can be more readily understood from thefollowing description taken in connection with the accompanyingdrawings, in which:

FIG. 1 is a simplified flowchart representation of the apparatus.

FIG. 2A is a perspective view of the apparatus.

FIG. 2B is a perspective side view of the apparatus of 2A.

FIG. 3A is a cross section view of a portion of the apparatus takenalong 3-3 of FIG. 2A.

FIG. 3B is a cross section view of a portion of the apparatus takenalong 3-3 of FIG. 2A.

FIG. 3C is a cross section view of a portion of the apparatus takenalong 3-3 of FIG. 2A.

FIG. 3D is a cross section view of a portion of the apparatus takenalong 3-3 of FIG. 2A.

FIG. 4A is a perspective view of a transfer member.

FIG. 4B is a perspective view of a transfer member.

FIG. 4C is a perspective view of a transfer member comprising segments.

FIG. 4D is a close up view of a transfer member segment from FIG. 4C.

FIG. 4E is a perspective view of a transfer member.

FIG. 5A is a perspective view of a cutting apparatus.

FIG. 5B is a cross section view of the cutting apparatus of FIG. 5Ataken along 5-5.

FIG. 6 is a cross section view of the receiving chamber taken along 6-6of FIG. 2A.

FIG. 6 is a perspective view of a cutting apparatus.

FIG. 7 is a cross section view of a metering system taken along 7-7 ofFIG. 2B.

FIG. 8 is a perspective view of an attachment system.

FIG. 9 exemplifies a pledget in a flat-out, uncompressed state.

FIG. 10 is a schematic representation of the apparatus with anattachment system and a conveyor.

DETAILED DESCRIPTION OF THE INVENTION

The following definitions may be useful in understanding the presentdisclosure.

“Compressed” refers herein to pressing or squeezing together orotherwise manipulating the size, shape, and volume to obtain a generallyelongated absorbent member having a vaginally insertable shape.

“Cross direction” (CD) refers herein to a direction that is not parallelwith, and usually perpendicular to, the machine direction.

“Fluid flow” refers herein to the flow of a medium. The path taken bythe medium defines a fluid flow path.

“Machine direction” (MD) refers herein to the direction of material flowthrough a process. In addition, relative placement and movement ofmaterial can be described as flowing in the machine direction through aprocess from upstream in the process to downstream in the process.

As used herein, “negative” pressure refers to less than atmosphericpressure.

The terms “pledget” and “tampon pledget” refer herein to a constructionof absorbent material prior to the compression of such construction intoa tampon as described below. A pledget may be in the form of a chevron.

Tampon pledgets are sometimes referred to as tampon “blanks” or“softwinds,” and the term “pledget” is intended to include such terms aswell.

As used herein, “positive” pressure refers to greater than atmosphericpressure.

As used herein, a “substrate” relates to a material or a combination ofmaterials that create a first plane and a second plane, opposite thefirst plane, such as, for example, a pledget, a plate, a sheet of glass,and a sheet of material. The substrate can comprise, for example,cellulose based materials, fibrous materials, metals, glass, silicatematerials, thermoplastics, and thermoset plastics.

The term “tampon,” as used herein, refers to any type of absorbentmember that is inserted into the vaginal cavity or other body cavitiesfor the absorption of fluid therefrom. Typically, tampons areconstructed from a generally elongated absorbent member that has beencompressed or formed into a vaginally insertable shape.

The term “vaginal cavity” refers herein to the internal genitalia of thehuman female in the pudendal region of the body. The term “vaginalcavity” as used herein is intended to refer to the space located betweenthe introitus of the vagina (sometimes referred to as the sphincter ofthe vagina) and the cervix and is not intended to include theinterlabial space, including the floor of the vestibule. The externalvisible genitalia generally are not included within the term “vaginalcavity” as used herein.

The term “volume” refers herein to the volume of the fibers and the voidspace within the pledget. Volume is measured by the multiplication ofthe length by the width by the thickness of the pledget.

The present disclosure relates to a method for delivering a discretecord to a transfer member utilizing fluid flow in a supply path. Oncedelivered, an orifice on the transfer member may move out of a fluidflow and deliver the discrete cord to an attachment system. The discretecord may be attached onto a substrate, such as, for example, a pledget.The apparatus may be timed with a conveyor that delivers the pledgetssuch that each discrete cord is delivered to a pledget.

In an exemplary configuration, a metered cord supply may advance adeployed cord supply to a supply path. The supply path is fluidlyconnected to the metered cord supply and comprises a transfer member, atransfer tube and a cutting apparatus. The transfer member comprises afirst surface, a second surface, and an orifice in the transfer memberfirst surface. The supply path contains a fluid flow capable of carryinga deployed cord supply. The fluid flow may be created by positivepressure, negative pressure, or combinations thereof. The fluid flow isdirected to deliver the deployed cord supply to the transfer memberabutting the cutting apparatus. In such an exemplary configuration, thecutting apparatus may be configured to cut a set amount of cord once thedeployed cord supply enters the orifice in the transfer member. Cuttingthe deployed cord supply creates a discrete cord. At least a portion ofthe discrete cord is within the orifice of the transfer member.

In an exemplary configuration, a metered cord supply advances a deployedcord supply to a supply path. The supply path is fluidly connected tothe metered cord supply and comprises a transfer member, a transfer tubeand a cutting apparatus. The transfer member comprises a first surface,a second surface, and an aperture through the transfer member connectingthe first surface to the second surface. The supply path contains afluid flow capable of carrying a deployed cord supply. The fluid flowmay be created by positive pressure, negative pressure, or combinationsthereof. The fluid flow is directed to deliver the deployed cord supplyto the transfer member first surface abutting the cutting apparatus. Insuch an exemplary configuration, the fluid flow is created by negativepressure from a vacuum source within a receiving chamber that abuts thesecond surface of the transfer member. The cutting apparatus may beconfigured to cut a set amount of cord once the deployed cord supplyenters an aperture in the transfer member. Cutting the deployed cordsupply creates a discrete cord. At least a portion of the discrete cordis within the aperture of the transfer member.

In an exemplary configuration, a metered cord supply advances a deployedcord supply to a supply path. The supply path is fluidly connected tothe metered cord supply and comprises a transfer member, a transfer tubeand a cutting apparatus. The transfer member comprises a first surface,a second surface, and an aperture through the transfer member connectingthe first surface to the second surface. The supply path contains afluid flow capable of carrying the deployed cord supply. The fluid flowis created by negative pressure from a vacuum source within a receivingchamber that abuts the second surface of the transfer member. The fluidflow is directed to deliver the metered supply cord to the transfermember first surface abutting the cutting apparatus. The deployed cordsupply enters the aperture in the transfer member. A tangible bodycauses the deployed cord supply to contact the first surface of thetransfer member at the same time or before the cutting apparatus cutsthe deployed cord supply to form a discrete cord. The transfer memberaperture moves out of the fluid flow taking the discrete cord.

The receiving chamber second end wall may comprise an outlet and atunnel. The receiving chamber outlet deflects the discrete cord, wherebythe cord is forced upon the transfer member second surface. The discretecord second end may conform to the transfer member first surface due tothe tangible body.

After exiting the receiving chamber outlet, the discrete cord comes incontact with an attachment system capable of joining the discrete cordto a substrate.

The transfer member, cutting apparatus, and a metering system may workin unison to deliver a discrete cord to each orifice of the transfermember. The transfer member, cutting apparatus, and metering system maywork in unison to deliver a discrete cord of any length. Alternatively,the transfer member, cutting apparatus, and metering system may be setto work in unison to deliver a discrete cord at a set rate, such as, forexample, to deliver discrete cords to the orifices at any desiredpattern, such as, for example, every other orifice. Alternatively, thetransfer member, cutting apparatus, and metering system may each becontrolled as an individual unit to control discrete cord delivery byspeeding up or slowing down one or two units while maintaining the otherunit(s) constant. In a configuration, the maximum velocity of theapparatus may be limited by the rate at which the attachment system mayattach a discrete cord to a substrate, such as, for example, the rate atwhich a sewing machine can sew the discrete cord.

The cord delivery system may comprise a cord supply and a meteringsystem. The metering system directs an end of a deployed cord supplyinto a supply path. The metering system may comprise any metering systemsuitable for feeding a cord into a system, such as, for example, anapron roll or an omega roll. The metering system may comprise two rollsworking in unison to direct the cord to the supply path. The meteringsystem controls the deployed cord supply length delivered to the cuttingapparatus. The metering system may be used as a phasing apparatus tocontrol discrete cord position, wherein the cord has a distinguishingfeature, such as, for example, a slub or a change in color.

The apparatus comprises a transfer member connected to a cuttingapparatus. The cutting apparatus is connected to a transfer tube. Thetransfer tube is connected to a cord delivery system. The transfermember, cutting apparatus, and the transfer tube form a supply path forthe deployed cord supply from the cord delivery system.

The supply path may contain a pressure source that creates a fluid flowdirected towards the transfer member. The fluid flow may carry a cord.The fluid flow may comprise any medium capable of carrying a cord, suchas, for example, air. The fluid flow may be created by one or morepressure sources that generate fluid movement, such as, for example, apositive displacement pump, a blower, a vane pump, and a venturi device.

The fluid flow may be created by positive pressure, negative pressure,and combinations thereof. Positive pressure may be introduced into thesupply path at the inlet of the transfer tube. Positive pressure may beintroduced before the metering system provided that the metering systemforms part of the fluid flow path. Changes in pressure may be introducedat any point along the supply path provided that the pressure does notcontradict the fluid flow direction.

Negative pressure may be created by a vacuum source connected to areceiving chamber abutting the second surface of the transfer member.The fluid flow velocity must exceed the required cord velocity in thesupply path. The required cord velocity is determined by the desiredlength of a discrete cord. The required fluid flow velocity will varydepending on the cord material, the desired length of the discrete cord,and any fluid flow losses or restrictions in the supply path. The fluidflow velocity should not be capable of damaging the supply cord.

Under negative pressure, the fluid flow velocity may be maintainedbetween a vacuum source and the cord delivery system such that the fluidflow velocity exceeds the cord velocity in the supply path by theapertures in the transfer member or by a combination of a hole and theaperture in the transfer member body comprising one aperture. Undernegative pressure only, the vacuum should be at least ten inches ofwater.

To maintain the fluid flow velocity, the supply path should minimize thenumber of bends, restrictions, and pressure leaks. Bends in the supplypath create pressure drops and may increase turbulence at particularportions of the supply path leading to reduced fluid flow velocity.Similarly, any leaks in the supply path will lead to a reduced fluidflow velocity. Leaks may be reduced, if not eliminated, by choosing theappropriate materials so that a seal will exist between the opening tothe cutting apparatus and the transfer member and between the transfermember and the receiving chamber. Compatible materials may allow for aconstant seal while still allowing the transfer member to bisect thefluid flow without adverse friction. In a non-limiting configuration,the transfer member comprises stainless steel and the cutting apparatusopening and the receiving chamber opening comprise nylon. Similarly, atight seal should exist between the transfer tube and the cuttingapparatus.

Without being bound by theory, it is believed that utilizing a fluidflow allows the cord supply to follow the fluid flow created by thepositive or negative pressure into an orifice of the transfer member.This allows for a fluid flow that adapts to the position of the orificein the supply path. The cord supply comprises a flexible cord that mayfollow the fluid flow to the orifice within the supply path. Withoutbeing bound by theory, it is believed that enabling the flexible cord tofollow the fluid flow allows for a faster production of discrete cords.Allowing the flexible cord to follow the fluid flow allows a cord toenter an orifice in the transfer member while moving the transfer memberorifice. This may increase the throughput of discrete cords to atransfer member.

The transfer member may comprise any tangible body that is capable ofreceiving an end of a deployed cord supply, capable of moving thedeployed cord supply, capable of moving a discrete cord, and that doesnot inhibit the fluid flow velocity. The transfer member comprises oneor more orifices on the first surface that receive the deployed cordsupply first end. The one or more orifices may be, for example,apertures that connect the transfer member first surface to the transfermember second surface or cavities with additional fluid channels that donot restrict the fluid flow, while restricting the first end of thedeployed cord supply. In a non-limiting configuration, one or moreapertures may each contain an obstruction that prevents the deployedcord supply from crossing the second surface of the transfer memberwithout inhibiting the fluid flow velocity.

In a non-limiting configuration, the transfer member may comprise aunitary body in the form of a ring with a plurality of orifices that areequidistantly spaced along a rim abutting the perimeter of the transfermember, a closed chain of segments wherein each segment comprises anorifice, or a body with one orifice and a hole. In a non-limitingconfiguration, the first surface of the transfer member is proximal to acutting apparatus and distal to an optional receiving chamber. In anon-limiting configuration, the second surface of the transfer member isproximal to an optional receiving chamber and distal to a cuttingapparatus.

The transfer member may comprise a unitary body in the form of a ringwith a plurality of orifices in the form of apertures that areequidistantly spaced along a rim abutting the perimeter of the transfermember. The ring comprises a central axis. The transfer member centralaxis may or may not be vertical or horizontal. The rigid body of thetransfer member may be connected to the central axis by one or morespokes.

Alternatively, the transfer member may comprise a closed chain ofsegments wherein each segment comprises an orifice in the form of anaperture. The closed chain comprises two or more segments connected toeach other, to a common axis, or a combination thereof. The transfermember segments move their respective orifices through the fluid flow,receive the discrete cord, and deliver it to the attachment system.

The segments comprise a first surface, a second surface, a front end, aback end, a width defined by the distance between the first surface andthe second surface, a height, and a length. The height and length of thesegment define a first surface area of the segment on the first surfaceand a second surface area of the segment on the second surface. Thesecond surface height may be different than the first surface heightmaking the first surface area a different dimension from the secondsurface area. The segments may be connected in a rigid closed structure,such as, for example, a ring or in a non-rigid closed structure, suchas, for example, a closed serpentine chain. The two or more segments areconnected such that the front end of a segment is connected to the backend of a second segment. In a rigid body, the one or more segmentscomprise a rim defined by the first surface area and the second surfacearea of the segments. The segment comprises an aperture that connectsthe first surface and the second surface.

The transfer member may comprise a body with one aperture. The body withone aperture has a length which is at least the width of the apertureplus the width of the greater of the two openings abutting the firstsurface and the second surface of the body. The body with one aperturereciprocates along a line or arc that moves the aperture through thefluid flow. The body with one aperture may comprise an additional holewhich connects the first surface of the body to the second surface ofthe body. The additional hole serves to maintain a fluid flow betweenthe cord supply and the receiving chamber when the aperture is outsidethe fluid flow.

The transfer member that is a body with one aperture reciprocates alonga line or arc that moves the aperture through the fluid flow. Theaperture may receive the cord supply at any point wherein the apertureis in the fluid flow. The cutting apparatus cuts the cord supplycreating a discrete cord. The aperture moves out of the fluid flow todeliver the discrete cord to the attachment system. The additional holemay maintain the fluid flow while the aperture is outside of the fluidflow.

The transfer member may comprise protuberances that extend from thewidth of the transfer member between the first surface and the secondsurface. The protuberances may extend from either width.

The apertures may be between about 4 mm² and 100 mm², such as, forexample, 50 mm², 40 mm², 30 mm², 20 mm², and 10 mm². The apertures maybe tapered from a larger opening on the first surface to a smalleropening on the second surface. The large opening on the first surfaceincreases the target for the deployed cord supply. The smaller openingon the second surface increases positional control of the discrete cordfirst end. Tapering allows increased air flow velocity through theaperture in the small end of the aperture compared to the large end.

In a non-limiting configuration wherein the attachment system is on thesecond surface of the transfer member, the width of the transfer membermay not be greater than the length of the discrete cord. In anon-limiting configuration, the width of the transfer member may not beless than half of the difference between the unsewn cord length and thepitch of the apertures in the transfer member. If the width of thetransfer member is less than the cord length minus the pitch of theapertures in the transfer member, a second end of the discrete cord mayenter the receiving chamber through the aperture following the aperturecontaining the first end of the discrete cord. This may cause the samediscrete cord to be sewn onto two pledgets.

In a non-limiting configuration, wherein the transfer member comprises arigid body comprised of segments that rotate about the central axis ofthe rigid body, the transfer member may be held by three or more supportwheels. The three support wheels may be in a triangle configuration.Alternatively, the transfer member may be held by four support wheels ina square configuration. In a non-limiting configuration, the rigid ringof segments may be rotated by a belt which is connected to a drivewheel.

The cutting apparatus comprises a cutting implement enabled to sever thedeployed cord supply to form a discrete cord, such as, for example, arigid knife, a laser, a rotary knife, a flexible knife, a guillotine, ora blade. In an exemplary configuration, a knife is attached to a rotaryaxis that rotates the knife through the supply path. A pressure surface,such as, for example, a rotating anvil, may be located opposite theknife. The knife may contact the pressure surface, severing the cordsupply.

In a non-limiting configuration, the cutting apparatus comprises avolumetric space joining the point at which the knife crosses the supplypath and the transfer member. The volumetric space allows for a smoothtransition between the point at which the knife crosses the supply pathand the opening that abuts the transfer member with minimal increase incross section area to maintain fluid flow velocity.

The opening is formed by a first edge, a second edge, a top wallconnecting the first edge to the second edge, and a bottom wallconnecting the first edge to second edge.

If the opening has a length greater than one pitch of the apertures onthe transfer member plus one width of the apertures, then the end of afirst discrete cord may enter the aperture for the second cord and/orthe beginning of the second cord may enter the aperture of the firstdiscrete cord.

The cutting apparatus may comprise an alternative fluid flow path whenthe knife rotates through the supply path. The alternative fluid flowpath ensures that a fluid flow exists when the knife bisects the fluidflow path taken by the deployed cord supply. The alternative fluid flowpath may be formed by a gap between the rotary axis for the knife and acasing for the knife. When the knife does not bisect the deployed cordsupply fluid flow path, this alternative fluid flow path is blocked bythe knife.

When the transfer member comprises more than one segment or is a rigidring, the cutting apparatus opening may be less than the area of theabutting first surface of a segment of the transfer member or a pitch ofthe rigid ring and the cutting apparatus opening follows the line ofmotion of the aperture of the transfer member. The length of the cuttingapparatus opening must be greater than the length of the segment.

Alternatively, when using a transfer member body comprising a singleaperture, the cutting apparatus opening may be less than the area of thefirst surface of the transfer member body. The cutting apparatus openinglength must be greater than the width of the hole plus the distancebetween the hole and the aperture.

The transfer tube may comprise an inlet in proximity or abutting themetering system of the cord delivery system and an outlet that is indirect contact with the cutting apparatus. The transfer tube may be madeof any material that can sustain a tubular form under the requiredamount of negative pressure, positive pressure, or combinations thereof,such as, for example, stainless steel and polycarbonate.

The transfer tube may be any suitable diameter, such as, for example, 1mm to 20 mm, such as, for example, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9mm, 10 mm, 15 mm. The transfer tube should have the least number ofbends possible to reduce the loss of air velocity in the transfer tube.

The metered cord supply comprises a metering system and a cord supply.The metering system may comprise any suitable feed mechanism, such as,for example, an omega roll, an apron roll, or a two roll nip. Themetering system controls the rate at which the cord supply is deployedto the supply path. In an exemplary configuration, the metering systemcomprises an apron roll and a drive wheel.

The cord supply can comprise any suitable material, including forexample, cotton, cellulose, rayon, polyolefins such as, for example,polyethylene or polypropylene, nylon, silk, polytetrafluoroethylene,wax, Teflon, or any other suitable materials.

The cord supply may be non-absorbent along at least the location ofattachment to the pledget. As used herein, the term “non-absorbent”refers to a structure that does not retain a significant portion ofdeposited fluid in its structure. The entire cord may be madenon-absorbent, if desired. The materials comprising the cord may beinherently non-wettable or hydrophobic, or they may be treated toprovide such properties. For example, a coating of wax may be applied tothe cord to decrease or eliminate its absorbency. The cord need notnecessarily be non-wicking, even if a non-absorbent cord is desired.

The cord supply can be formed by any suitable formation method and inany suitable configuration, such as, for example, one or more cords,strings, finger covers, ribbons, an extension of a material of thedevice, or combinations thereof.

The cord supply may alternate between a distinguishing feature and alength of plain cord. One discrete cord may be made up of adistinguishing feature and one or more lengths of plain cord. Thedistinguishing feature may be a slub. The slub may be attached onto thepledget. The length of plain cord may extend beyond the pledget. Thelength of the slub and the length of the plain cord are predetermined inthe cord supply. The cord supply may comprise a continuous cord thatalternates between slubs and non-slub portions or lengths of plain cord.

The discrete cord may be any suitable length, such as, for example,between 10 mm and 200 mm, between 20 mm and 150 mm, between 20 mm and100 mm, 200 mm or less, 150 mm or less, 100 mm or less, such as forexample, 90 mm, 80 mm, 70 mm, 60 mm, 50 mm, 40 mm, 30 mm, 20 mm, 10 mm,9 mm, 8 mm, 7 mm, 6 mm, 5 mm, 4 mm, 3 mm, 2 mm, or 1 mm. The slub may beany suitable length, such as, for example, 100 mm or less, such as forexample, 50 mm, 45 mm, 40 mm, 35 mm, 30 mm, 25 mm, 20 mm, 15 mm, 10 mm,5 mm, 4 mm, 3 mm, 2 mm, or 1 mm. The slub may be a percentage of thetotal discrete cord length, such as, for example, 50%, 45%, 40%, 35%,30%, 25%, 20%, 15%, 10%, or 5%.

The cord supply may be wound around any volumetric shape wherein thecord makes the outer surface of the shape, such as, for example, a cone,a spool, a cylinder, or a bobbin. The cord supply may be wound aroundtwo fixed ends of a tangible shape. Alternatively, the cord supply maybe layered such that it rests upon itself.

In a non-limiting configuration, the deployed cord supply is forced tocontact the transfer member by one or more physical constraints, one ormore intangible constraints, or combinations thereof. Without beingbound by theory, it is believed that forcing the deployed cord supply tocontact the transfer member allows for better discrete cord control bypreventing the discrete cord from continuing to follow the fluid flowafter it is separated from the deployed cord supply. Forcing thediscrete cord to contact the transfer member enables the transfer memberto transfer the discrete cord out of the fluid flow to the attachmentsystem. The type of physical or intangible constraint may determine thedistance that can be covered by the transfer member.

In a non-limiting configuration, the physical constraint comprises atangible body capable of creating friction between the deployed cordsupply or the discrete cord and the transfer member. The tangible bodymay be any suitable shape, such as, for example, a spring loaded wheelor a wheel made of a compliant material.

The tangible body may be located on the first surface of the transfermember, housed within the cutting apparatus immediately adjacent to thesecond edge of the cutting apparatus opening. The tangible body forms anip causing the discrete cord to contact the first surface of thetransfer member. In an exemplary configuration, the tangible bodycomprises a spring loaded wheel. The spring loaded wheel rotates at thevelocity of the transfer member forcing the discrete cord against thefirst surface of the transfer member.

The tangible body may be located on the first surface of the transfermember outside of the cutting apparatus and immediately adjacent to thesecond edge of the cutting apparatus opening. In a non-limitingconfiguration, a plurality of tangible bodies may be used to maintainthe discrete cord against the first surface of the transfer member untilthe discrete cord reaches the attachment system.

In a non-limiting configuration, an intangible constraint comprising oneor more additional pressure sources may be used to force the deployedcord supply to contact the transfer member, creating friction betweenthe deployed cord supply or the discrete cord and the transfer member.In an exemplary configuration, the intangible constraint may comprise avacuum source within the transfer member enabled to create a vacuumagainst the first surface, second surface, or within the orifice of thetransfer member.

In a non-limiting configuration, the transfer member may comprise anactive clamp configured to grip the deployed cord supply or discretecord inside the orifice of the transfer member. The active clamp may bespring loaded. The active clamp may force a portion of the discrete cordto contact an inner surface of the orifice. The active clamp may retractto release the discrete cord upon reaching the attachment system.

The apparatus may comprise a receiving chamber. The receiving chambermay comprise any suitable volumetric space comprising at least twoopenings to the volumetric space. In a non-limiting configuration, thereceiving chamber has an opening comprising a first end wall, a secondend wall, a bottom wall connecting the first end wall and the second endwall, and a top wall connecting the first end wall and second end wall.The receiving chamber may be tapered.

When deployed to vacuum, the receiving chamber comprises a back wallenclosing the receiving chamber and an opening to the vacuum source. Theopening to the vacuum source may be located anywhere in the receivingchamber. The receiving chamber opening is formed by a first end wall, asecond end wall, the bottom wall, and the top wall. The receivingchamber opening should be an area that allows for a continuous fluidflow through the transfer member. If the opening does not enable acontinuous fluid flow, the fluid flow can pulse.

Alternatively, when deployed to vacuum, the receiving chamber may be anyvolumetric geometry provided that the opening to the receiving chambercomprises an opening with an arc-shaped slot, comprising a first endwall and a second end wall, whose radius is concentric and equal to theradius passing through the centers of the openings on the rim of thering shaped transfer member. The arc-shaped slot may have a length equalto one pitch of the apertures on the transfer member plus or minus thewidth of an aperture.

The second end wall may comprise an outlet abutting the transfer member.The outlet may have a cross section area between 0.5 mm² to 30 mm². Theoutlet may pinch the discrete cord as it exits the receiving chamber byforcing it to come into contact with the rim of the second surface ofthe transfer member.

A tunnel may be joined to the receiving chamber at the outlet.Alternatively, a tunnel may be integral with the receiving chamber atthe outlet. The integral tunnel may be a separate piece that connects tothe opening of the receiving chamber and contacts the transfer memberacting as the opening to the receiving chamber with a tunnel at thesecond end wall outlet. The tunnel can be of any suitable length suchas, for example, 1 mm to 40 mm.

The receiving chamber may have a vacuum source. The vacuum source maydraw between about 10 inches of water and about 80 inches of water, suchas, for example, 30 inches of water, 35 inches of water, 40 inches ofwater, 45 inches of water, 50 inches of water, 55 inches of water, 60inches of water, 65 inches of water, 70 inches of water, or 75 inches ofwater.

The attachment system may be any system capable of joining a discretecord to a substrate. The attachment system is downstream of the supplypath. The attachment system may abut the first surface or the secondsurface of the transfer member. The attachment system may abut thesupply path. The attachment system may comprise any known means ofattachment, such as, for example, a sewing apparatus, an adhesive,ultrasonics, heat, a stapling device, or combinations thereof.

The attachment system may be a sewing apparatus. The substrate may bemoved along the stitch plate by a star wheel, by a set of protuberanceson the transfer member rim, the sewing apparatus, and combinationsthereof. The sewing apparatus may be configured to sew the discrete cordto a substrate by any number of desired stitches for a length ofdiscrete cord.

The substrate may be a pledget. The pledget may comprise rayon, cotton,or combinations of both materials. These materials have a proven recordof suitability for use in the human body. The rayon used in theabsorbent material may be any suitable type typically used in disposableabsorbent articles intended for in vivo use. Such acceptable types ofrayon include GALAXY Rayon (a tri-lobed rayon structure) available as6140 Rayon from Acordis Fibers Ltd., of Hollywall, England. SARILLE LRayon (a round fiber rayon), also available from Acordis Fibers Ltd. isalso suitable. Any suitable cotton material may be used in the absorbentmaterial. Suitable cotton materials include, long fiber cotton, shortfiber cotton, cotton linters, T-fiber cotton, card strips, and combercotton. The cotton may be scoured and bleached cotton absorbent with aglycerin finish, or other suitable finish.

The pledget may comprise a first end, middle section, and a second endalong a longitudinal axis. The first end may also correspond to thewithdrawal end to which a withdrawal cord may be attached. The secondend may also correspond to the insertion end. The pledget may compriseabsorbent layers comprising absorbent fiber materials.

The pledget may be any suitable shape, size, material, or constructionfor compression or formation into a tampon having a vaginally insertableshape. The pledget may be generally square or rectangular or take onother shapes such as trapezoidal, triangular, hemispherical, chevron orhourglass shapes.

The pledget may be a laminar structure comprised of integral or discretelayers. The absorbent material may comprise 100% rayon fibers or 100%cotton fibers. The absorbent material may comprise a combination ofrayon and cotton fibers in any suitable combination. The absorbentmaterial may comprise greater than about 25%, 30% or 40% rayon fibersand the balance of the absorbent material comprising cotton fibers. Theabsorbent material may comprise greater than about 50% rayon fibers withcotton fibers comprising the balance of the absorbent material. Theabsorbent material may comprise greater than about 60, 70, 75, 80 or 90%rayon fibers and the balance of the absorbent material comprising cottonfibers. In one layered configuration, each of the layers may compriseessentially 100% of the same material, such as outer layers of 100%rayon and an intermediate layer of 100% cotton. A Super Plus absorbencytampon may be made from a pledget comprising about 100% rayon fibers. ASuper absorbency or Regular absorbency tampon may be made from a pledgetcomprising about 25% cotton and about 75% rayon fibers. A Juniorabsorbency tampon may be made from a pledget comprising about 50% cottonand about 50% rayon fibers.

The pledget may be constructed from a wide variety of liquid-absorbingmaterials commonly used in absorbent articles such as rayon (includingtri-lobal and conventional rayon fibers), cotton, or comminuted woodpulp which is generally referred to as airfelt. Examples of othersuitable absorbent materials include, but are not limited to, crepedcellulose wadding; meltblown polymers including coform; chemicallystiffened, modified or cross-linked cellulosic fibers; synthetic fiberssuch as crimped polyester fibers; peat moss; foam; tissue includingtissue wraps and tissue laminates; or any equivalent material orcombinations of materials, or mixtures thereof.

Typical absorbent materials may comprise cotton, rayon folded tissues,woven materials, nonwoven webs, synthetic and natural fibers, orsheeting. The pledget and any component thereof, may comprise a singlematerial or a combination of materials. Additionally, superabsorbentmaterials, such as superabsorbent polymers or absorbent gelling andopen-celled foam materials, may be incorporated into the tampon.

Examples of the absorbent fiber materials used for the absorbing layerinclude hydrophilic fibers such as cotton, rayon and synthetic fiber.Single or multiple fiber webs, nonwoven or woven fabrics, preferablyhaving a weight of 150 g/m² to 1,500 g/m² and a thickness ofsubstantially 0.1 mm to 0.9 mm are lapped over another absorbent fibermaterial to form an absorbing layer having a thickness of 1.0 mm to 15mm and preferably having a thickness of 2.0 mm to 10 mm are used as theabsorbing layer.

Fiber webs and nonwoven fabrics may be shaped by card webbing,air-laying method, wet laid method and the like, on a base such as asynthetic fiber sheet. Hydrophobic fibers or hydrophobic fiberscomprising a hydrophilic property may also be comprised in the absorbinglayer with the hydrophilic fibers. In addition, compounds having a waterabsorbing property, such as polymers with a high water absorbingproperty, may be comprised in the absorbing layer. The surface materialwith liquid permeability is made of nonwoven fabrics formed byhydrophobic fibers or mesh films, to which mesh treatment has beenperformed. The type of nonwoven fabrics used for the surface material isnot particularly limited and examples include spunbond nonwoven fabrics,spunlace nonwoven fabrics and thermal bond nonwoven fabrics.

The hydrophobic fiber which makes up the nonwoven fabrics is notparticularly limited and examples include fibers of polyester,polypropylene and polyethylene. The weight of the nonwoven fabrics isbetween 8 g/m² to 40 g/m².

A typical size for the pledget prior to compression may be from about 30or 40 mm to about 60, 70, 80, 90 or 100 mm in length and from about 40or 50 mm to about 70, 75, 80, 85, or 90 mm in width. The typical rangefor the overall basis weight may be from about 150, 200, or 250 gsm toabout 600, 800, 1000 or 1100 gsm.

In a non-limiting configuration, a pledget may advance in a machinedirection along a conveyor track to the sewing apparatus that engagesthe discrete cord. The pledget may be oriented such that the first endis perpendicular with the machine direction. In such a non-limitingconfiguration, the discrete cord sewing apparatus may be configured tosew a portion of a single discrete cord to the pledget. The sewn portionof the single discrete cord may be sewn along the longitudinal axis ofthe pledget in the first end of the pledget. Alternatively, the sewnportion of the single discrete cord may be sewn along the longitudinalaxis of the pledget in the middle section. The single discrete cordextends beyond the pledget. The discrete cord may be sewn onto thepledget by one or more stitches, such as, for example, between 1 and 20stitches, such as, for example, 2 stitches, 3 stitches, 4 stitches, 5stitches, 6 stitches, 7 stitches, 8 stitches, 9 stitches, or 10stitches.

The conveyor may comprise an infeed that places substrates, such aspledgets, on the conveyor. The conveyer and the infeed may be adjustedto space the pledgets apart based on the discrete cord setting. Theconveyer may feed the pledget to a sewing apparatus. The conveyor may betimed so that the number of pledgets is timed with the number ofdiscrete cords to have one pledget for every one discrete cord.

The metering system, transfer member, cutting apparatus, and conveyormay work in unison to deliver a discrete cord to a substrate. Themetering system, transfer member, cutting apparatus, and conveyor maywork in unison to deliver multiple discrete cords to a substrate. In anon-limiting configuration, the metering system, transfer member,cutting apparatus, and conveyor may be phased to control the location ofthe discrete cord on the substrate. Phasing the metering system, cuttingapparatus, transfer member, and conveyor allows a discrete cord to beattached to a pledget within an acceptable error of a predeterminedlocation on the pledget.

While the present disclosure discusses an apparatus for delivering adiscrete cord to a pledget, it is to be appreciated that the methods andapparatuses disclosed herein may be used to deliver a cord to any formof substrate that has a discrete cord attached onto the substrate.

FIG. 1 shows a simplified flowchart of the apparatus 100. The apparatus100 comprises a metered cord supply 200 and a supply path 300. Themetered cord supply 200 comprises a cord supply 210 and a meteringsystem 220. The supply path 300 comprises a cutting apparatus 500 and atransfer member 400. The apparatus 100 may further comprise a receivingchamber 700. As shown in FIG. 1, a pressure source 205 may be placedbetween the metered cord supply 200 and the supply path 300, after thereceiving chamber 700, or in both locations. The transfer member 400moves out of the supply path 300 towards an attachment system 800.

FIGS. 2A-B show an exemplary configuration of the apparatus 100. Theapparatus 100 comprises a transfer member 400 connected to a cuttingapparatus 500. The cutting apparatus 500 is connected to a transfer tube600. The transfer tube 600 is connected to a metering system 220. Thetransfer member 400 rotates about a central axis 450. A receivingchamber 700 abuts the transfer member 400.

The transfer member 400 comprises a plurality of orifices 412 in theform of apertures 410 that connect a first surface of the transfermember 420 to a second surface of the transfer member 430. The distancebetween the first surface 420 and the second surface 430 may equal thewidth 425 of the transfer member 400. The apertures 410 are locatedwithin a rim 440 of the transfer member 400. The transfer memberapertures 410 are equidistant. The transfer member 400 may comprise oneor more protuberances 490 that extend beyond the circumference of therim 440. The protuberances 490 may engage with a substrate to help movethe substrate.

The transfer member 400 may comprise one or more spokes 470 connectingthe transfer member rim 440 to a central axis 450. The transfer member400 may rotate in either a clockwise or counter clockwise direction.

The transfer tube 600 comprises an inlet 610 connected to the meteringsystem 220 and an outlet 620 (not shown in FIG. 2A) that is in directcontact with an inlet 575 of the cutting apparatus 500. The transfertube 600 inlet 610 may be partially open to the atmosphere. The deployedcord supply 230 enters the transfer tube 600 at the inlet 610.

FIGS. 3A-D show a development of the stepped cross sectional viewresulting from section line 3-3 of FIG. 2A. FIGS. 3A-D show the cuttingapparatus 500, the transfer member 400, and the receiving chamber 700.The transfer member 400 comprises a first surface 420, a second surface430, and orifices 412 in the form of apertures 410 that are equidistantwithin the rim 440. The cutting apparatus 500 comprises an opening 540made up of a first edge 520, a second edge 530, a bottom wall 525connecting the first edge 520 and the second edge 530, and a top wall(not shown) connecting the first edge 520 and the second edge 530. Thecutting apparatus 500 comprises a knife 510 configured to sever aportion of the deployed cord supply 230 into a discrete cord 900. Theknife 510 rotates along an alternative fluid flow path 555 formed by agap between the rotary axis 550 for the knife 510 and the casing 560 forthe knife 510. The knife 510 is rotated about a rotary axis 550 andbisects the fluid flow 310 of the deployed cord supply 230 whilecontacting a pressure surface 515. The alternate fluid flow path 555maintains a fluid flow 310 when the knife 510 bisects the deployed cordsupply 230. The opening 540 to the cutting apparatus 500 is in directcontact with the first surface 420 of the transfer member 400.

The receiving chamber 700 comprises a first end wall 720, a second endwall 730, a lower wall 725 connecting the first end wall 720 and thesecond end wall 730, and a upper wall (not shown) connecting the firstend wall 720 and the second end wall 730. A receiving chamber comprisesan opening 740 which is in direct contact with the second surface 430 ofthe transfer member 400. The receiving chamber 700 second end wall 730comprises an outlet 750 that abuts the transfer member 400. Thereceiving chamber 700 may comprise an outlet 750 and a tunnel 755.

FIGS. 3A-C illustrate three snapshots of how the apparatus creates anddelivers a discrete cord 900. As shown in FIGS. 3A-C, an aperture 410 ofthe transfer member 400 receives a discrete cord 900 as it moves throughthe fluid flow 310 in a Machine Direction. As shown in FIGS. 3A-C, thecutting apparatus 500 second end wall 530 may comprise a tangible body565. Alternatively, as shown in FIG. 3D, the transfer member 400 maycomprise an active clamp 460.

The discrete cord 900 is a predetermined length. The discrete cord 900has a first end 910 and a second end 920. The predetermined length maycomprise a slub 930 and a non-slub portion 940. Alternatively, the cordsupply may comprise a continuous cord that consists only of a non-slubportion 940. The slub 930 may be made of the same material as the restof the cord or of a different material.

As shown in FIG. 3A, a transfer member aperture 410 enters the fluidflow 310 while another transfer member aperture 410 exits the fluid flow310 with a discrete cord 900. The entering transfer member aperture 410maintains the fluid flow 310 creating a path for the deployed cordsupply 230.

As shown in FIG. 3B, a tangible body 565 deflects the deployed cordsupply 230 against the transfer member 400 concurrent with a knife 510cutting the deployed cord supply 230 to form a discrete cord 900. Thediscrete cord 900 first end 910 crosses through the transfer memberaperture 410 and enters the receiving chamber 700. The discrete cord 900first end 910 is deflected towards the second surface 430 of thetransfer member 400 by the outlet 750 in the receiving chamber 700. Thetransfer member aperture 410 moves between the cutting apparatus 500 andthe receiving chamber 700 through the fluid flow 310. The knife 510bisects the fluid flow 310 and the deployed cord supply 230 may followthe alternate fluid flow path 555 of the cutting apparatus 500.

As shown in FIG. 3C, the discrete cord 900 has a first end 910 and asecond end 920. The transfer member aperture 410 has begun exiting thefluid flow 310 with a discrete cord 900 that is in contact with thetangible body 565 and the first surface 420 of the transfer member 400.An aperture 410 has entered the fluid flow 310. The deployed cord supply230 follows the fluid flow 310 towards the aperture 410 while the knife510 rotates along the alternative fluid flow path 555 formed by a gapbetween the rotary axis 550 for the knife 510 and the casing 560 for theknife 510. One of ordinary skill in the art would comprehend that FIGS.3A-C represent a portion of a transfer member which may comprise aplurality of equidistant apertures or, alternatively, segmentscomprising apertures which are connected in a closed chain such that afirst segment will be reintroduced into the system after the lastsegment of the transfer member.

Alternatively, as shown in FIG. 3D, the discrete cord 900 may be heldinside of the aperture 410 by an active clamp 460.

FIGS. 4A-E show exemplary representations of transfer members 400. Asshown in FIGS. 4A-C, the transfer member 400 comprises a plurality oforifices 412 in the form of apertures 410 that cross through the firstsurface 420 of the transfer member rim 440 to the second surface 430 ofthe transfer member rim 440. The distance between the first surface 420and the second surface 430 may equal the width 425 of the transfermember 400. Protuberances 490 may extend beyond the circumference of thetransfer member rim 440. The transfer member 400 rotates about a centralaxis 450.

As shown in FIG. 4A, the transfer member 400 may comprise one or morespokes 470 connecting the transfer member rim 440 to a central axis 450.As shown in FIG. 4B, the transfer member 400 may comprise a rim 440 witha central axis 450 held by three or more support wheels 480. Foursupport wheels 480 may hold the transfer member in place in a squareconfiguration. Three support wheels 480 may hold the transfer member 400in place in a triangle configuration (not shown).

FIG. 4C shows a transfer member 400 comprising a plurality of segments405, wherein each of the segments 405 comprise an orifice 412 in theform of an aperture 410. The transfer member 400 comprises one or morespokes 470 connecting the transfer member rim 440 to a central axis 450.The closed chain 415 may be in the form of a ring. Alternatively, itshall be understood that the closed chain 415 may be serpentine (notshown).

FIG. 4D shows a close up perspective view of a transfer member segment405 of FIG. 4C. The segment 405 comprises a first surface 420, a secondsurface 430, a front end 422, a back end 424, a width 425 defined by thedistance between the first surface 420 and the second surface 430, aheight 426, and a length 428. The segment 405 comprises an orifice 412in the form of an aperture 410 connecting the first surface 420 with thesecond surface 430. The segment 405 may comprise protuberances 490extending radially outward from the segment 405.

FIG. 4E shows a transfer member 400 comprising a body 402 with oneaperture 410. The body 402 comprises a first surface 420, a secondsurface 430, a front end 442, a back end 444, a width 425 defined by thedistance between the first surface 420 and the second surface 430, aheight 446, and a length 448. The body 402 comprises an orifice 412 inthe form of an aperture 410 connecting the first surface 420 with thesecond surface 430. The body 402 may comprise a hole 436 that connectsthe first surface 420 with the second surface 430. The body 402 maycomprise protuberances 490 extending radially outward from the body 402.

FIGS. 5A and 5B show an exemplary configuration for the cuttingapparatus 500. FIG. 5A is a perspective view of the cutting apparatus500. FIG. 5B is a sectional view of the cutting apparatus 500 along 5-5of FIG. 5A. The cutting apparatus 500 of FIGS. 5A and 5B comprises arotary axis 550 within a housing 505. The housing 505 comprises an inlet575 and an opening 540 to the cutting apparatus 500. The opening 540 tothe cutting apparatus 500 comprises a first edge 520 (not shown in FIG.5B) and a second edge 530 that are connected by a bottom wall 525 and anupper wall 535.

FIG. 5B is a sectional view of the cutting apparatus 500 along 5-5 ofFIG. 5A. The cutting apparatus 500 comprises a rotary axis 550 aboutwhich a knife 510 rotates. The cutting apparatus 500 further comprises apressure surface 515. The opening 540 to the cutting apparatus 500 maymatch the opening to the receiving chamber in terms of total surfacearea.

FIG. 6 shows a cross section of an exemplary receiving chamber 700 alongline 6-6 of FIG. 2A. The receiving chamber 700 has an opening 740 and avacuum source creating the fluid flow 310. The opening comprises asecond end wall 730, an upper wall 735 connecting a first end wall (notshown) to the second end wall 730, and a lower wall 725 connecting thefirst end wall (not shown) in the figure to the second end wall 730. Thesecond end wall 730 of the receiving chamber 700 comprises an outlet750. A tunnel 760, integral to the receiving chamber 700, extends beyondthe second end wall 730.

FIG. 7 shows a side elevation view of a metering system 220. Themetering system 220 may be an apron roll. The apron roll may comprise adrive wheel 222, a belt 224, wrap wheel 226, and an idler wheel 228.

FIG. 8 shows an attachment system 800 in the form of a sewing apparatus810. The sewing apparatus 810 comprises a sewing needle 820 and a stitchplate 840 that runs along a machine direction. A feed wheel 830 islocated above the stitch plate 840 configured to engage with thesubstrate. The feed wheel 830 may be in the form of a star wheel. Thestitch plate 840 is directly under the sewing needle 820.

FIG. 9 exemplifies a tampon pledget 1000 in a flat-out, uncompressedstate. The absorbent material 1010 may form a tampon pledget 1000. Thetampon pledget 1000 comprises an insertion end 1020, a withdrawal end1030, a first longitudinal edge 1040, and a second longitudinal edge1050. Compression of a tampon pledget 1000 can form a compressedabsorbent member. The pledget 1000 can have an overwrap 1060 and anadditional optional second overwrap 1070.

FIG. 10 shows a schematic representation of a potential process 1100.The schematic representation shows a conveyor 1110, a conveyor infeed1120 capable of placing pledgets 1000 on the conveyor 1110, a meteredcord supply 200 including a cord supply 210 and a metering system 220, acutting apparatus 500, a transfer member 400, a receiving chamber 700,and an attachment system 800. As shown in FIG. 10, a conveyor infeed1120 places chevron shaped pledgets 1000 on the conveyor 1110. Thepledgets 1000 move in the Machine Direction (MD) on the conveyor 1110towards the transfer member 400. The transfer member 400 receives adiscrete cord 900 and moves the discrete cord 900 to the attachmentsystem 800 or sewing apparatus 810 where it is joined to a pledget 1000.Each pledget 1000 receives one discrete cord 900.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of delivering a discrete cord to atransfer member, the method comprising: a. providing a supply pathfluidly connected to a metered cord supply, wherein the supply pathcomprises a fluid flow, a transfer member, and a cutting apparatus;wherein the transfer member comprises a first surface, a second surface,and one or more orifices on the first surface; b. moving a deployed cordsupply towards the transfer member through the supply path by the fluidflow; c. moving the deployed cord supply into an orifice of the transfermember; and d. cutting the deployed cord supply to create a discretecord comprising a first end and a second end; wherein a portion of thediscrete cord is in the orifice to the transfer member.
 2. The method ofclaim 1, wherein the method further comprises moving the orifice out ofthe fluid flow and contacting the discrete cord with an attachmentsystem.
 3. The method of claim 1, wherein the cutting apparatuscomprises a cutting implement selected from the group consisting of arigid knife, a laser, a rotary knife, a flexible knife, a guillotine, ora blade.
 4. The method of claim 1, wherein cutting the deployed cordsupply to create a discrete cord further comprises bisecting the fluidflow with a knife connected to a rotary axis.
 5. The method of claim 1,wherein a tangible body contacts the deployed cord supply before thedeployed cord supply is cut to create a discrete cord.
 6. The method ofclaim 2, wherein the method further comprises the deployed cord supplyentering a receiving chamber.
 7. The method of claim 6, wherein movingthe orifice out of the fluid flow further comprises deflecting thediscrete cord by an outlet in the receiving chamber.
 8. The method ofclaim 2, wherein the method further comprises repeating the steps ofmoving a deployed cord supply towards the transfer member through thesupply path by the fluid flow; moving the deployed cord supply into anorifice of the transfer member; cutting the deployed cord supply tocreate a discrete cord comprising a first end and a second end; andmoving the orifice out of the fluid flow and contacting the discretecord with an attachment system.
 9. The method of claim 2, wherein themetered cord supply, the cutting apparatus, and the transfer member workin unison to provide one discrete cord to every orifice in the firstsurface of the transfer member moving through the fluid flow.
 10. Themethod of claim 2, wherein moving the orifice out of the fluid flowfurther comprises rotating the transfer member about a central axis. 11.The method of claim 1, wherein the discrete cord is between 10 mm and200 mm in length.
 12. A method of delivering a discrete cord to anattachment system, the method comprising: a. providing a supply pathfluidly connected to a metered cord supply, wherein the supply pathcomprises a receiving chamber, a fluid flow, a cutting apparatus, and atransfer member comprising a plurality of apertures, a first surface incontact with the cutting apparatus, and a second surface in contact withthe receiving chamber; b. moving a deployed cord supply towards thetransfer member through the supply path by the fluid flow; c. moving thedeployed cord supply into an aperture of the transfer member; and d.cutting the deployed cord supply to create a discrete cord comprising afirst end and a second end; wherein a portion of the discrete cord is inthe aperture of the transfer member; e. moving the aperture out of thefluid flow; and f. contacting the discrete cord with an attachmentsystem.
 13. The method of claim 12, wherein cutting the deployed cordsupply to create a discrete cord further comprises bisecting the fluidflow with a knife connected to a rotary axis.
 14. The method of claim12, wherein a tangible body contacts the deployed cord supply before thedeployed cord supply is cut to create a discrete cord.
 15. The method ofclaim 12, wherein moving the transfer member out of the supply pathfurther comprises deflecting the discrete cord by an outlet in thereceiving chamber.
 16. The method of claim 12, wherein the methodfurther comprises repeating the steps of drawing the deployed cordsupply to the receiving chamber through an aperture in the transfermember, cutting the deployed cord supply to create a discrete cordcomprising a first end and a second end, and moving the aperture out ofthe fluid flow.
 17. The method of claim 12, wherein the metered cordsupply, the cutting apparatus, and the transfer member work in unisonproviding one discrete cord to every aperture of the transfer member.18. The method of claim 12, wherein moving the aperture out of the fluidflow further comprises rotating the transfer member about a centralaxis.
 19. The method of claim 12, wherein the discrete cord is between10 mm and 200 mm in length.
 20. A method of delivering a discrete cordto an attachment system, the method comprising: a. providing a supplypath fluidly connected to a metered cord supply, wherein the supply pathcomprises a receiving chamber, a fluid flow, a cutting apparatus, and atransfer member comprising a plurality of apertures, a first surface incontact with the cutting apparatus, and a second surface in contact withthe receiving chamber; b. moving a deployed cord supply towards thetransfer member through the supply path by the fluid flow; c. moving thedeployed cord supply into an aperture of the transfer member; and d.contacting the deployed cord supply with a spring loaded wheel; e.cutting the deployed cord supply with a knife connected to a rotary axisto create a discrete cord comprising a first end and a second end;wherein a portion of the discrete cord is in the aperture of thetransfer member; f. deflecting the discrete cord by an outlet in thereceiving chamber; g. moving the transfer member aperture out of thefluid flow; h. contacting the discrete cord with an attachment system;and i. repeating steps b-h; wherein the metered cord supply, the cuttingapparatus, and the transfer member work in unison providing one discretecord to every aperture of the transfer member that enters the fluidflow.